SURGE ANALYSIS OF

PUMPING SYSTEMS
Thomas C
Th Crowley,
l PE & Weston
W Engel,
E l PE - Carollo
C ll
Stewart Noland, PE – Crist Engineers
Scott Foster, PE – Flow Science
October 14, 2014
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Oklahoma
Okl h City,
Cit OK
– Central Arkansas Water Little Rock, AR
– SUA Stillwater, OK
• Recommendations
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
 Factors Causing Surge

• Primary Surge Transients

– Pump Startup
– Pump Shutdown
– Power Loss
– Valve Shutdown
• Secondary Surge Transients
– Air Valve
– Water Column Separation
 Factors Causing Surge

• Primary Surge Transients

– Pump Startup
– Pump Shutdown
– Power Loss
– Valve Shutdown
• Secondary Surge Transients
– Air Valve
– Water Column Separation
 Factors Causing Surge

• Primary Surge Transients

– Pump Startup
– Pump Shutdown
– Power Loss
– Valve Shutdown
• Secondary Surge Transients
– Air Valve
 Factors Causing Surge

• Primary Surge Transients

– Pump Startup
– Pump Shutdown
– Power Loss
– Valve Shutdown
• Secondary Surge Transients
– Air Valve
– Water Column Separation
 Factors Causing Surge

• Primary Surge Transients

– Pump Startup
– Pump Shutdown
– Power Loss
– Valve Shutdown
• Secondary Surge Transients
– Air Valve
– Water Column Separation
Factors Causing Surge
Air Valve Caused Surge
Air Valve Caused Surge
 Factors Causing Surge

• Primary Surge Transients

– Pump Startup
– Pump Shutdown
– Power Loss
– Valve Shutdown
• Secondary Surge Transients
– Air Valve
– Water Column Separation @ High Spots
Water Column Separation
Water Column Separation
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
 Factors Influencing Surge
F
Formation
ti
• Pipeline Properties
– Pipeline profile (particularly high points)
– Pipeline and lining Material
– Configuration (Storage locations)
• Pipe Appurtenances
– Air valve Location and Types
– Valve Types and opening/Closing
– Type of Check Valves
• Pump
P Features
F t
– Pump performance curves and operating speeds
– Rotational moment of inertia’s for pump/motor
p p/
assemblies
Common Surge Misconceptions
• Pipeline velocities must be low to reduce the
effects of water hammer
• Surges only occur in long pipelines
• The noise and knock in a system
y is an indicator of
the magnitude of a surge
• Surge protection devices should be installed on an
experimental basis because it is not possible to
accurately determine the magnitude of surges
g p
• The use of surge protection devices are not
economically viable
• Pressures in a system must be high before
dangerous surges can occur
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
How can you determine if Surge is
an Issue?
I ?
• Banging
g g Noises and Vibration
– Pressure waves bouncing from piping
– Check valve slamming
• F
Frequentt pipe
i breaks
b k in
i the
th Same
S
places especially near pump station or
low/high
o / g po points
ts in the
t e system.
syste
• System Measurements (transients
occur too quickly for normal PT’s)
• Difficult to observe due to infrequent
occurrence and difficulty in monitoring.
Why Should You Care About Water
Hammer.
H
• Catastrophic Service Breaks
• Pipe Materials Behave Differently:
– Plastic: Lower p
propagation
p g but more
susceptible to fatigue from cyclic loading.
– Steel, Concrete: Higher pressure rise but
less susceptible to cyclic loading.
loading
• Contamination Potential
• Damage to system instrumentation
(Gauges, Flowmeters, etc.)
• Control and Alarm Issues
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
 Types of Surge Suppression
E i
Equipment t - Passive
P i
• Pump Control Valves Characteristics:
 Types of Surge Suppression
E i
Equipment-t Passive
P i
• Pump Check Valve Characteristics:
 Types of Surge Suppression
E i
Equipment-t Passive
P i
• Controlled Pump
p Startup/Shutdown
p
– Provide wirth “S-curve feature” to Time
with Valves
– Not all Soft Starts Created Equal
– Voltage/Torque
g / q Control More Important
p
than Current.
 Types of Surge Suppression
E i
Equipmentt
• Pump Design Features:
– Pump Curve
– Pump Impeller Moment of Inertia
– Anti Reverse - Ratchet
 Types of Surge Suppression
E i
Equipment t - Active
A ti
• Air/Vacuum Relief Valves (Size and
Location)
 Types of Surge Suppression
E i
Equipment t - Active
A ti
• Air/Vacuum Relief Valves (Size and
Location)
• AVV Surge Check Devices
 Types of Surge Suppression
D i
Devices - Active
A ti
• Surge Anticipation Valves
• Surge Tanks
– Bladder
Bl dd
– Hydropneumatic
– Surge Towers
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
CAW Maumelle Pump Station
Hi t
History
600

550

500

450

Elevation (fft)
400

350

300

250

200
0 1 2 3 4 5 6 7 8 9
Distance (miles)
Breaks on  Pipeline Elevation
Breaks on 
72‐inch Pipeline Pressure
48 inch
48‐inch
Protect, Replace or Bypass Area of 
Highest Pressures
 ARV

48” 60” 30”

12” ARV
30 mgd
48” 60 30”
”

12”
30 mgd
36” 24”

12”
48” 30 mgd
ARV 24”
36”
24”
60”
12”
30 mgd
ARV
15 mgd
15 mgd 30”
30
24” 48” Pumps 1‐4
36”
ARV
14”
15 mgd 48”
24”

E
30 mgd 48”
72”
Pumps 5‐7 Figure
g 1 –Existing
g Schematic Maumelle Pump p Station
Lake Maumelle Pump Station and Transmission Main
Preliminary Design Technical Memorandum
Central Arkansas Water
 Surge Analysis Assumptions
• All Air/Vacuum Relief Valves equipped with controlled
venting/slow
g/ closing.
g
• All seven pumps are operating (174 mgd at 333-341
TDH)
• One of the river crossings is out of service (highest
velocity)
l )
• Pump Control Valves Close within 60 seconds of power
loss.
• All fi
five S
Surge A ti i t V
Anticipator l
Valves (SAV’ ) ffully
(SAV’s) ll open
following activation (Pressure below 75 psig).
• SAV’s Remain in operation for 30 seconds and close
within 260 seconds.
seconds
• Both the 72-inch and 48-inch Transmission Mains are
hydraulically connected.
 At all times Max HGL < 1.33 x Pressure 
Rating

Proper Operation of CAV’s Crucial 
to protection scheme.

Areas of High 
Potential for Vapor 
Cavity Formation 
and Collapse

Figure
g 2 –Existing
g System
y Lake Maumelle Transmission Mains
Lake Maumelle Pump Station and Transmission Main Preliminary
Design Technical Memorandum
Central Arkansas Water
 At all times Max HGL < 1.33 x Pressure 
Rating

CAV’s inadequate to prevent vapor 
cavity formation

Areas of High 
Potential for Vapor 
Cavity Formation 
and Collapse
 Repressurization
and potential for 
and potential for
VC collapse

Potential cycling of 
event very 
damaging to PCCP.

Figure
g 2 –Existing
g System
y Lake Maumelle Transmission Mains
Rapid Drop of  Lake Maumelle Pump Station and Transmission Main Preliminary
Design Technical Memorandum
Pressure at PS Central Arkansas Water
 Surge Analysis Mitigation
• Install Three 12 ft diameter x 60 ft long
g
surge tanks with 45% air.
• Install tanks at pump station.
• Install
I ll new valves
l to close
l within
i hi 5
seconds of power failure at pump
station.
• Retain existing SAV’s for increased level
of protection.
• Install Surge Checks on CAV’s at
stations further down the pipes.
CAV ‘s require 
controlled venting
CAV ‘s require 
controlled venting
controlled venting
 ARV

30”
Dual Disc Check Valve – Lug Type 48” 48” 60”
VFD
12”
12 ARV
Dismantling Joint
30 mgd
DMJ
30”
60”
ARV VFD
12”

DM
24”

MJ
30 mgd

36”
ARV
15 mgd
24” 48” 24”
12”
12
14” 48” 30 mgd
ARV 36”
15 mgd 24” 60” 24”
12”
VFD 30 mgd
30”
30 mgd

36”
J
DM
J
DM

30” 48”
M

30”
30
J
DM

30”

H
48”
60”
60 60”
60 72”
72 Figure
g 5–Proposed
p Schematic Surgeg Tanks Option
p 1
Lake Maumelle Pump Station and Transmission Main
Preliminary Design Technical Memorandum
Air Compressor (Typ of 4) Central Arkansas Water
CAW Surge Suppression System
CAW Surge Suppression System
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
 M
36”

42”
42
48”
FM M
Existing Ka

20”

Kaw  36” 36” 36”

36”
Reservoir 9 mgd, 173 psig VT Pump
1,000 HP (typ of 2)
aw Raw Wate

Large Pumps
Legend 24” M

F Flowmeter
M
M
Strainer
er Pipeline S

Electric Actuated Control Valve M

Globe Style Check Valve
M
4 mgd, 78 psig VT Pump
Constant Speed Pump 200 HP (typ of 3)
Schematic

36”
S ll P
Small Pumps
Variable Speed Pump
V

24” 24”
4MG Raw Water 
Butterfly Isolation Valve Storage Tank
To Stillwater 
To Stillwater 24
24”
24”
WTP
12”
24” 42”
FIGURE 1.1

From Stillwater  To OSU WTP
36”
WTP
New Water Treatment Plant and Capacities Study Update
Draft Report August 2012
 2‐inch combination
Air Valve (typ)
Sta. 633+48
Man way
Existing Kaw Raw Water Pipeline

Sta. 1931+68 Sta. 1307+92
(Tank Farm) Man way
e Profile

Horizontal Scale: 
0.5 inch = 2 miles
FIGURE 2.3

New Water Treatment Plant and Capacities Study Update

Draft Report August 2012
 Surge Analysis Results

• Potentially Damaging Surge Waves

were occurring due to:
– Large Pump Startup/Shutdown
– Lack of Proper Air/Vacuum Relief Valves
 Sta. 633+ 48 Sta. 525+ 00 Sta. 117+ 43
4‐inch CAV 4‐inch CAV 4 inch CAV
4‐inch CAV

Sta. 1307+92
Recom

4‐inch CAV
mmended Lo
ocations for CAV’s

Horizontal Scale: 
0.5 inch = 2 miles
Sta. 1677+51 Sta. 756+05 Sta. 368+75
2‐inch CAV (relocated) 2‐inch CAV (relocated) 2‐inch CAV (relocated)
Sta. 00+00
2‐inch CAV (relocated)
FIGURE 4.1

Sta. 190+29
2‐inch CAV (relocated)

New Water Treatment Plant and Capacities Study Update

Final Report October 20122
 Agenda

• Factors Causingg Surge

g in Pumping
p g Systems
y
• Factors Influencing Surge Severity
• Why Should I Care about Surge?
• Types of Surge Suppression Systems
• Case Studies:
– Okl
Oklahoma
h City,
Cit OK
– Central Arkansas Water
– Stillwater, OK
• Recommendations
 Conclusions and
R
Recommendations
d ti
• Do not assume that low velocities = No
Surge
• Always
y perform
p a surge
g hydraulic
y
analysis:
– On new systems
– On existing systems to change conditions
– To determine timing of pump/valve startup.
• System
S t conditions
diti will
ill dictate
di t t solution:
l ti
– Active or Passive
– Type of Active
Questions

55